CURA-12081 Scarf seam

CMakeLists.txt

@@ -142,7 +142,6 @@ set(engine_SRCS # Except main.cpp.
         src/utils/ListPolyIt.cpp
         src/utils/Matrix4x3D.cpp
         src/utils/MinimumSpanningTree.cpp
-        src/utils/Point3LL.cpp
         src/utils/PolygonConnector.cpp
         src/utils/PolygonsPointIndex.cpp
         src/utils/PolygonsSegmentIndex.cpp
@@ -157,6 +156,8 @@ set(engine_SRCS # Except main.cpp.
         src/utils/VoxelUtils.cpp
         src/utils/MixedPolylineStitcher.cpp
 
+        src/geometry/Point2LL.cpp
+        src/geometry/Point3LL.cpp
         src/geometry/Polygon.cpp
         src/geometry/Shape.cpp
         src/geometry/PointsSet.cpp

include/ExtruderPlan.h

@@ -191,7 +191,7 @@ class ExtruderPlan
     /*!
      * @return distance between p0 and p1 as well as the time spend on the segment
      */
-    std::pair<double, double> getPointToPointTime(const Point2LL& p0, const Point2LL& p1, const GCodePath& path);
+    std::pair<double, double> getPointToPointTime(const Point3LL& p0, const Point3LL& p1, const GCodePath& path);
 
     /*!
      * Compute naive time estimates (without accounting for slow down at corners etc.) and naive material estimates.

include/GCodePathConfig.h

@@ -20,7 +20,7 @@ struct GCodePathConfig
 {
     static constexpr double FAN_SPEED_DEFAULT = -1.0;
 
-    coord_t z_offset{}; //<! vertical offset from 'full' layer height
+    coord_t z_offset{}; //<! vertical offset from 'full' layer height, to be applied to the whole path
     PrintFeatureType type{}; //!< name of the feature type
     coord_t line_width{}; //!< width of the line extruded
     coord_t layer_thickness{}; //!< current layer height in micron

include/InsetOrderOptimizer.h

@@ -57,7 +57,9 @@ class InsetOrderOptimizer
         const ZSeamConfig& z_seam_config,
         const std::vector<VariableWidthLines>& paths,
         const Point2LL& model_center_point,
-        const Shape& disallowed_areas_for_seams = {});
+        const Shape& disallowed_areas_for_seams = {},
+        const bool scarf_seam = false,
+        const bool smooth_speed = false);
 
     /*!
      * Adds the insets to the given layer plan.
@@ -110,6 +112,8 @@ class InsetOrderOptimizer
     const LayerIndex layer_nr_;
     const Point2LL model_center_point_; // Center of the model (= all meshes) axis-aligned bounding-box.
     Shape disallowed_areas_for_seams_;
+    const bool scarf_seam_;
+    const bool smooth_speed_;
 
     std::vector<std::vector<const Polygon*>> inset_polys_; // vector of vectors holding the inset polygons
     Shape retraction_region_; // After printing an outer wall, move into this region so that retractions do not leave visible blobs. Calculated lazily if needed (see

include/LayerPlan.h

@@ -57,6 +57,14 @@ class LayerPlan : public NoCopy
 #endif
 
 public:
+    // 'AdjustCoasting'; because split-up paths from the same extruder (with no travel moves between them) should count as the same path w.r.t. coasting.
+    enum class AdjustCoasting
+    {
+        AsNormal,
+        CoastEntirePath,
+        ContinueCoasting
+    };
+
     const PathConfigStorage configs_storage_; //!< The line configs for this layer for each feature type
     const coord_t z_;
     coord_t final_travel_z_;
@@ -360,14 +368,15 @@ class LayerPlan : public NoCopy
      * \param fan_speed Fan speed override for this path.
      */
     void addExtrusionMove(
-        const Point2LL p,
+        const Point3LL& p,
         const GCodePathConfig& config,
         const SpaceFillType space_fill_type,
         const Ratio& flow = 1.0_r,
         const Ratio width_factor = 1.0_r,
         const bool spiralize = false,
         const Ratio speed_factor = 1.0_r,
-        const double fan_speed = GCodePathConfig::FAN_SPEED_DEFAULT);
+        const double fan_speed = GCodePathConfig::FAN_SPEED_DEFAULT,
+        const bool travel_to_z = true);
 
     /*!
      * Add polygon to the gcode starting at vertex \p startIdx
@@ -452,8 +461,8 @@ class LayerPlan : public NoCopy
      * the first bridge segment.
      */
     void addWallLine(
-        const Point2LL& p0,
-        const Point2LL& p1,
+        const Point3LL& p0,
+        const Point3LL& p1,
         const Settings& settings,
         const GCodePathConfig& default_config,
         const GCodePathConfig& roofing_config,
@@ -462,7 +471,8 @@ class LayerPlan : public NoCopy
         const Ratio width_factor,
         double& non_bridge_line_volume,
         Ratio speed_factor,
-        double distance_to_bridge_start);
+        double distance_to_bridge_start,
+        const bool travel_to_z = true);
 
     /*!
      * Add a wall to the g-code starting at vertex \p start_idx
@@ -481,7 +491,7 @@ class LayerPlan : public NoCopy
      */
     void addWall(
         const Polygon& wall,
-        int start_idx,
+        size_t start_idx,
         const Settings& settings,
         const GCodePathConfig& default_config,
         const GCodePathConfig& roofing_config,
@@ -513,7 +523,7 @@ class LayerPlan : public NoCopy
      */
     void addWall(
         const ExtrusionLine& wall,
-        int start_idx,
+        size_t start_idx,
         const Settings& settings,
         const GCodePathConfig& default_config,
         const GCodePathConfig& roofing_config,
@@ -523,7 +533,9 @@ class LayerPlan : public NoCopy
         bool always_retract,
         const bool is_closed,
         const bool is_reversed,
-        const bool is_linked_path);
+        const bool is_linked_path,
+        const bool scarf_seam = false,
+        const bool smooth_speed = false);
 
     /*!
      * Add an infill wall to the g-code
@@ -676,7 +688,7 @@ class LayerPlan : public NoCopy
      * \return The index of the first supported vertex - if no vertices are supported, start_idx is returned
      */
     template<typename T>
-    unsigned locateFirstSupportedVertex(const T& wall, const unsigned start_idx) const
+    size_t locateFirstSupportedVertex(const T& wall, const size_t start_idx) const
     {
         if (bridge_wall_mask_.empty() && seam_overhang_mask_.empty())
         {
@@ -685,7 +697,7 @@ class LayerPlan : public NoCopy
 
         const auto air_below = bridge_wall_mask_.unionPolygons(seam_overhang_mask_);
 
-        unsigned curr_idx = start_idx;
+        size_t curr_idx = start_idx;
 
         while (true)
         {
@@ -736,14 +748,17 @@ class LayerPlan : public NoCopy
      * \param path_idx The index into LayerPlan::paths for the next path to be
      * written to GCode.
      * \param layer_thickness The height of the current layer.
+     * \param insertTempOnTime A function that inserts temperature changes at a given time.
+     * \param coasting_adjust Paths can be split up, so we need to know when to continue coasting from last, or even coast the entire path.
      * \return Whether any GCode has been written for the path.
      */
     bool writePathWithCoasting(
         GCodeExport& gcode,
         const size_t extruder_plan_idx,
         const size_t path_idx,
         const coord_t layer_thickness,
-        const std::function<void(const double, const int64_t)> insertTempOnTime);
+        const std::function<void(const double, const int64_t)> insertTempOnTime,
+        const std::pair<AdjustCoasting, double> coasting_adjust);
 
     /*!
      * Applying speed corrections for minimal layer times and determine the fanSpeed.
@@ -820,6 +835,114 @@ class LayerPlan : public NoCopy
         const coord_t wipe_dist,
         const Ratio flow_ratio,
         const double fan_speed);
+
+    /*!
+     *  @brief Send a GCodePath line to the communication object, applying proper Z offsets
+     *  @param path The path to be sent
+     *  @param position The start position (which is not included in the path points)
+     *  @param extrude_speed The actual used extrusion speed
+     */
+    void sendLineTo(const GCodePath& path, const Point3LL& position, const double extrude_speed);
+
+    /*!
+     *  @brief Write a travel move and properly apply the various Z offsets
+     *  @param gcode The actual GCode exporter
+     *  @param position The position to move to. The Z coordinate is an offset to the current layer position
+     *  @param speed The actual used speed
+     *  @param path_z_offset The global path Z offset to be applied
+     *  @note This function is to be used when dealing with 3D coordinates. If you have 2D coordinates, just call gcode.writeTravel()
+     */
+    void writeTravelRelativeZ(GCodeExport& gcode, const Point3LL& position, const Velocity& speed, const coord_t path_z_offset);
+
+    /*!
+     * \brief Write an extrusion move and properly apply the various Z offsets
+     * \param gcode The actual GCode exporter
+     * \param position The position to move to. The Z coordinate is an offset to the current layer position
+     * \param speed The actual used speed
+     * \param path_z_offset The global path Z offset to be applied
+     * \param extrusion_mm3_per_mm The desired flow rate
+     * \param feature The current feature being printed
+     * \param update_extrusion_offset whether to update the extrusion offset to match the current flow rate
+     */
+    void writeExtrusionRelativeZ(
+        GCodeExport& gcode,
+        const Point3LL& position,
+        const Velocity& speed,
+        const coord_t path_z_offset,
+        double extrusion_mm3_per_mm,
+        PrintFeatureType feature,
+        bool update_extrusion_offset = false);
+
+    /*!
+     * \brief Add a wall to the gcode with optimized order
+     * \param wall The full wall to be added
+     * \param wall_length The pre-calculated full wall length
+     * \param start_idx The index of the point where to start printing the wall
+     * \param direction The direction along which to print the wall, which should be 1 or -1
+     * \param max_index The last index to be used when iterating over the wall segments
+     * \param settings The settings which should apply to this wall added to the layer plan
+     * \param default_config The config with which to print the wall lines that are not spanning a bridge or are exposed to air
+     * \param roofing_config The config with which to print the wall lines that are exposed to air
+     * \param bridge_config The config with which to print the wall lines that are spanning a bridge
+     * \param flow_ratio The ratio with which to multiply the extrusion amount
+     * \param line_width_ratio The line width ratio to be applied
+     * \param non_bridge_line_volume A pseudo-volume that is derived from the print speed and flow of the non-bridge lines that have preceded this lin
+     * \param min_bridge_line_len The minimum line width to allow an extrusion move to be processed as a bridge move
+     * \param always_retract Whether to force a retraction when moving to the start of the polygon (used for outer walls)
+     * \param is_small_feature Indicates whether the wall is so small that it should be processed differently
+     * \param small_feature_speed_factor The speed factor to be applied to small feature walls
+     * \param max_area_deviation The maximum allowed area deviation to split a segment into pieces
+     * \param max_resolution The maximum resolution to split a segment into pieces
+     * \param scarf_seam_length The length of the scarf joint seam, which may be 0 if there is none
+     * \param scarf_seam_start_ratio The ratio of the line thickness to start the scarf seam with
+     * \param scarf_split_distance The maximum length of a segment to apply the scarf seam gradient, longer segments will be splitted
+     * \param scarf_max_z_offset The maximum Z offset te be applied at the lowest position of the scarf seam
+     * \param speed_split_distance The maximum length of a segment to apply the acceleration/deceleration gradient, longer segments will be splitted
+     * \param start_speed_ratio The ratio of the top speed to be applied when starting the segment, then accelerate gradually to full speed
+     * \param accelerate_length The pre-calculated length of the acceleration phase
+     * \param end_speed_ratio The ratio of the top speed to be applied when finishing a segment
+     * \param decelerate_length The pre-calculated length of the deceleration phase
+     * \param is_scarf_closure Indicates whether this function is called to make the scarf closure (overlap over the first scarf pass) or
+     *                         the normal first pass of the wall
+     */
+    void addSplitWall(
+        const ExtrusionLine& wall,
+        const coord_t wall_length,
+        size_t start_idx,
+        const int direction,
+        const size_t max_index,
+        const Settings& settings,
+        const GCodePathConfig& default_config,
+        const GCodePathConfig& roofing_config,
+        const GCodePathConfig& bridge_config,
+        const double flow_ratio,
+        const Ratio line_width_ratio,
+        double& non_bridge_line_volume,
+        const coord_t min_bridge_line_len,
+        const bool always_retract,
+        const bool is_small_feature,
+        Ratio small_feature_speed_factor,
+        const coord_t max_area_deviation,
+        const auto max_resolution,
+        const auto scarf_seam_length,
+        const auto scarf_seam_start_ratio,
+        const auto scarf_split_distance,
+        const coord_t scarf_max_z_offset,
+        const coord_t speed_split_distance,
+        const Ratio start_speed_ratio,
+        const coord_t accelerate_length,
+        const Ratio end_speed_ratio,
+        const coord_t decelerate_length,
+        const bool is_scarf_closure);
+
+    /*!
+     * \brief Helper function to calculate the distance from the start of the current wall line to the first bridge segment
+     * \param wall The currently processed wall
+     * \param current_index The index of the currently processed point
+     * \param min_bridge_line_len The minimum line width to allow an extrusion move to be processed as a bridge move
+     * \return The distance from the start of the current wall line to the first bridge segment
+     */
+    coord_t computeDistanceToBridgeStart(const ExtrusionLine& wall, const size_t current_index, const coord_t min_bridge_line_len) const;
 };
 
 } // namespace cura

include/communication/ArcusCommunication.h

@@ -86,7 +86,7 @@ class ArcusCommunication : public Communication
      * This may indicate the starting position (or any other jump in the path).
      * \param position The current position to start the next line at.
      */
-    void sendCurrentPosition(const Point2LL& position) override;
+    void sendCurrentPosition(const Point3LL& position) override;
 
     /*
      * \brief Sends a message to indicate that all the slicing is done.
@@ -113,7 +113,7 @@ class ArcusCommunication : public Communication
      * visualisation of the layer.
      *
      * This will be called after all the polygons and lines of this layer are
-     * sent via sendPolygons, sendPolygon and sendLineTo. This will flush all
+     * sent via sendLineTo. This will flush all
      * visualised data for one layer in one go.
      * \param layer_nr The layer that was completed.
      * \param z The z-coordinate of the top side of the layer.
@@ -132,7 +132,7 @@ class ArcusCommunication : public Communication
      * \param line_thickness The thickness (in the Z direction) of the line.
      * \param velocity The velocity of printing this polygon.
      */
-    void sendLineTo(const PrintFeatureType& type, const Point2LL& to, const coord_t& line_width, const coord_t& line_thickness, const Velocity& velocity) override;
+    void sendLineTo(const PrintFeatureType& type, const Point3LL& to, const coord_t& line_width, const coord_t& line_thickness, const Velocity& velocity) override;
 
     /*
      * \brief Send the sliced layer data to the front-end after the optimisation
@@ -142,34 +142,6 @@ class ArcusCommunication : public Communication
      */
     void sendOptimizedLayerData() override;
 
-    /*
-     * \brief Send a polygon to the front-end to display in layer view.
-     *
-     * The polygons are not actually flushed until ``sendLayerComplete`` is
-     * called.
-     * \param type The type of print feature the polygon represents (infill,
-     * wall, support, etc).
-     * \param polygon The shape to visualise.
-     * \param line_width The width of the lines in this polygon.
-     * \param line_thickness The thickness (in the Z direction) of the polygon.
-     * \param velocity The velocity of printing this polygon.
-     */
-    void sendPolygon(const PrintFeatureType& type, const Polygon& polygon, const coord_t& line_width, const coord_t& line_thickness, const Velocity& velocity) override;
-
-    /*
-     * \brief Send polygons to the front-end to display in layer view.
-     *
-     * The polygons may not actually be flushed until ``sendLayerComplete`` is
-     * called.
-     * \param type The type of print feature the polygons represent (infill,
-     * wall, support, etc).
-     * \param polygons The shapes to visualise.
-     * \param line_width The width of the lines in these polygons.
-     * \param line_thickness The thickness (in the Z direction) of the polygons.
-     * \param velocity The velocity of printing these polygons.
-     */
-    void sendPolygons(const PrintFeatureType& type, const Shape& polygons, const coord_t& line_width, const coord_t& line_thickness, const Velocity& velocity) override;
-
     /*
      * \brief Send an estimate of how long the print would take and how much
      * material it would use.
@@ -182,15 +154,13 @@ class ArcusCommunication : public Communication
     void sendProgress(double progress) const override;
 
     /*
-     * \brief Set which extruder is being used for the following calls to
-     * ``sendPolygon``, ``sendPolygons`` and ``sendLineTo``.
+     * \brief Set which extruder is being used for the following calls to ``sendLineTo``.
      * \param extruder The new extruder to send data for.
      */
     void setExtruderForSend(const ExtruderTrain& extruder) override;
 
     /*
-     * \brief Set which layer is being used for the following calls to
-     * ``sendPolygon``, ``sendPolygons`` and ``sendLineTo``.
+     * \brief Set which layer is being used for the following calls to ``sendLineTo``.
      * \param layer_nr The index of the layer to send data for. This is zero-
      * indexed but may be negative for raft layers.
      */